Needle punch machine



Dec. 3, 1963 A. M. SMITH :1 3,112,549 NEEDLE PUNCH MACHINE Onginal Filed May 13, 1960 3 Sheets-Sheet l INVENTOR. flfx/ /vafe 53 7 I Dec. 3, 1963 A. M. SMITH u NEEDLE PUNCH MACHINE 3 Sheets-Sheet 2 Onginal Filed May 13, 1960 amwafe 9591/74] INVENTOR.

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Dec. 3, 1963 A. M. SMITH n 3,112,549

NEEDLE PUNCH MACHINE Onginal Filed May 13, 1960 3 Sheets-Sheet 3 INVEN TOR. Ala Amaze #SV/l/ J United States Patent 3,112,549 NEEDLE PUNCH MAQHENE Alexander M. Smith Ill, Ellrin, N.C., assignor to Chatham Manufacturing Company, Eilrin, N.C., a corporation of North Carolina Original application May 13, 1%0, Ser. No. 29,115. Divided and this application Sept. 26, 1961, Ser. No. 149,139

7 Ulnims. (ill. 23-4) The present invention relates to an improved needle punch machine for making a new and improved needled or non-woven fabric from an improved method of needling. More particularly, the invention contemplates an improved needle punch machine for interlacing and/or interlooping fibers in a loosely matted material, the improved needle punch machine carrying out the interlacing and/or interlooping of fibers according to an improved method.

This application is a division of my copending application, Serial No. 29,115, filed May 13, 1960, and is entitled to the filing date thereof.

Non-woven unbonded fabric structures deriving coherence and strength from inner fiber entanglement and accompanying frictional forces are commonly known as felt, and such material has been heretofore made by mechanical working of wool or wool-like materials and some cases by a process known as needle punching wherein loosely matted fibers are rearranged and entangled by barbed or hooked needles passing therethrough. The advent of synthetic fibers in recent years has resulted in increased use of needle punching in the manufacture of non-woven, felt-like products. The present invention is intended for use in producing non-woven fabrics from either natural fibers or synthetic fibers or a blend of natural and synthetic fiber-s, the produced non-woven fabrics being especially desirable for use in blankets or outerwear fabrics and the like. :Also, the present invention may be used in producing a non-woven fabric from two or more webs of loosely matted fibers having a scrim of woven, non-woven, or bonded fabric being interposed between the webs or batts of loosely matted fibers.

Conventional methods and machines now in use for felting have not proved entirely satisfactory in tightly interlacing and/or interlooping fibers as the punching needles have not been arranged to coordinate with each other in such a manner as to provide an interlacing and/ or interlooping of fibers from both surfaces of the web or webs being treated. Further, conventional machines have required passing the material to be treated through the machines more than one time in order to obtain adequate entan lement of fibers. In some cases, the machines have been rather heavy and cumbersome and slow moving in order to obtain necessary entanglement of loosely matted fibers fed thereto and the resulting product has been lacking in strength and density. Further, the products heretofore made by needle punching are subject to elongation because of the lack of proper interlacing and/or interlooping. Because of the lack of coherence, uniform napping properties of both surfaces of the resulting product could not be obtained and such products lost much of their strength upon a subsequent napping operation such as when blankets or the like were made from the product.

Throughout the specification Wherever the term interlacing is used, it is to define a binding together of fibers from one outside surface of a web to the other outside surface of the web. interlacing of fibers is somewhat similar to sewing machine action although it does not depend on a continuous threaded action. On the other hand, the term interlooping as used throughout the specification is intended to mean a binding of fibers through loops of other fibers below the surface of the Web. Interlooping is akin to knitting as it provides entanglement of fibers by loop engagement; however, it is confined to the subsurface interior of the web as distinguished from interlacing wherein fibers from one surface are carried to the opposite surface and intermingled with fibers from that surface in the course of being returned toward the original surface.

Accordingly, an object of the present invention is to provide an improved needling or punching a web or batt of a loosely matted fiber which will result in fabricating fibers by tightly interlacing and/or interlooping, giving the resulting product more strength, coherence, density, uniform napping properties, and less elongation in use.

Ancillary to the preceding object, it is a further object of the present invention to provide an improved type of needle punching apparatus for interlacing and/or interlooping the loosely matted fibers in a web or batt to produce an improved needled or non-woven material.

Still another object of the present invention is to provide an improved needle punch machine for needling loosely matted fibers to tightly interlace and interloop the same so that there is less loss of strength when the resulting product is napped.

A further object of the present invention is to provide an improved apparatus which will tightly interlace loosely matted fibers in a web upon one pass of the web through the apparatus, the resulting product having extremely high separation strength.

Another object of the present invention is to provide an improved apparatus for needling a loosely matted material, the apparatus being capable of compressing the .rnaterial as well as tightly interlacing and/or interlooping the fibers in the material.

Still a further object of the present invention is to provide a method and apparatus which will provide an extremely high number of punches or penetrations of the material in a square inch upon passage of the material through the machine once.

A further object of the present invention is to provide a method and apparatus wherein the interlacing and/or intcrlooping of fibers may be controlled by coordinating the advancement of the web through the machine with alternate penetration of needle patterns from each side of the Web to be punched.

A still further object of the present invention is to provide an improved method and apparatus for needling material to produce a needled or non-woven fabric having uniform and substantially identical characteristics on both surfaces or faces. This is an important consideration when the product is subjected to subsequent finishing operations, particularly napping.

These and other objects and advantages of the present invention will appear more fully in the following specification, claims and drawings in which:

FIGURE 1 is a side elevational view of an improved apparatus for accomplishing the improved novel method of producing a needled or non-woven fabric material;

FIGURE 2 is an end elevationm view looking from the right of FIGURE 1;

FIGURE 3 is an enlarged vertical sectional view partly in elevation and taken on the line 33 of FIGURE 2;

FIGURE 4 is an enlarged fragmentary view of a web guide plate taken on the line 4-4 of FIGURE 3 and illustrating the pattern of needles for accomplishing the high number of penetrations per square inch of material treated;

FIGURE 5 is an enlarged fragmentary view taken on the line 5-5 of FIGURE 4 and showing a typical barbed needle;

FIGURES 6 and 7 illustrate progressive steps of interlacing fibers as the web of material passes through the apparatus of the present invention;

FIGURE 8 is a view illustrating interlacing combined with interlooping within the interior of the web, the view showing for purpose of illustration only, needles penetrating from opposite sides of the web at the same time; and

FIGURE 9 is a schematic view of the needle path through the material resulting from coordination between needle movement and advancement of the material according to the method of the present invention.

Referring now to the drawings wherein like character and reference numerals represent like or similar parts, and in particular to FIGURE 1, it will be noted that a web or batt of loosely matted fibers generally designated at it? is moving from the left to the right of the figure through the needle punch machine generally desgina ed at 12. Passing from the machine 12 at the right hand side of the figure is a needled or non-Woven fabric material shown in broken lines and designated by the numeral 14. It will be understood that the web or batt of fibrous material may be continuously fed from a conventional carding machine (not shown) where the fibers are combed and loosely formed into the web or it may be supplied from rolls of such material after the material has been taken from a carding machine and formed in a roll. If desirable and depending upon the type of end product to be made, the web shown as It in FIGURE 1 may be formed from two or more layers of loosely matted fibers l6 aind l3 separated by a scrim which is usually loosely woven fabric Zll, as best shown in FIGURES 6 to 8 inclusively.

In order to accomplish the novel method of the present invention resulting in the interlacing and/or intcrlooping of the fibers in the web it the web is advanced in intermittent step-by-step motion between opposed patterns of needles generally designated at 22 and 24 (FIGURE 3). The needle patterns 22 and 24 are arranged to travel in a path perpendicular to the direction of travel of the 'web and to the surfaces of the web and the motion of the needle patterns is coordinated with the step-by-step motion of the web as will be explained in more detail. Needle patterns 22 and 24 are made up of an array of downwardly extending needles 26 and an array of upwardly extending needles 28. The paths of travel of the needle patterns 22 and 24 are substantially mirror-image paths of each other and are, thus, substantially identical but reversed of each other. One way of providing mirrorimage paths for the patterns of needles is by arranging the needles 26 of needle pattern 22 to travel point-onpoint with the needles 28 of the needle pattern 24. The needle patterns 22 and 24 are arranged to alternately penetrate the web while the web is traveling through a confined throat 3i defined by a pair of spaced apart web guide plates 32 and 34. The guide plates 32 and 34 are provided with curved inlet portions 36 and 38 respectively, which define a gradually decreasing inieed portion 40 for the throat 3G. The infeed portion 46* of the throat tapers down to a thickness to which the web is compressed by the needling, this thickness being substantially the thickness of the finished needled or non-woven product produced by the needle punching machine 12. The needles 26 and 28 are each provided with a plurality of barbs 42 on their surface for engaging the fibers as they penetrate the web.

Referring now to FIGURES 6 to 9 inclusive, it will (be assumed that the web 19 is moving through the throat 30 between the guide plates 32 and 34 in the direction of the arrow A in step-'by-step motion. The step-by-step motion of the web it is coordinated with the movement of the needles 26 and 28 so that either set of the needles initially penetrate the surface of the web when the web is making its step motion. This causes the fibers adjacent the surfaces of the web to be caught by the needle Points and moved in a substantially horizontal direction for a short distance. Then the web stops and the needles of the particular pattern 22 or 24 which is penetrating, continue the perpendicular movement through the web, the herbs d2 of needles carrying with them some of the fibers near the surface of the web which have been oriented horizontally as well as other unoriented fibers picked up near the surface during the course of needle movement through the web. When the needles of a particular pattern 22 or 24- such as the needles 26 as shown in FIGURE 6 have passed completely through the web with their lowermost barb 42 positioned adjacent a surface of the web or extending out of the web no greater than one-half inch, the needles 26 are then withdrawn from the web and while the web is still stationary.

When the needles 26 have been withdrawn from the web and just as penetration by the opposed array of needles 28 begins, the web makes another increment of movement in the direction of the arrow A. Since the needles 28 enter the web at the point where the respective aligned needles 25 projected through the web, some of i the loop fibers previously brought through by the needles 2% are picked up near the surface of penetration by the needles 2% and are carried along horizontally with other surface fibers. The web it then stops but penetration of the needles 2% continues through the web until the barbs closest to the needle points are adjacent to or extend no greater than one-half of an inch pass the other surface of the web. Then the needles 28 are withdrawn while the web is stationary and once they are withdrawn the above-described operation is repeated. It will be understood that the needle patterns 22 and 24 reciprocate into and out of the web, the arrangement being such that there is alternate penetration of the web from opposite sides by the needle patterns 22 and 24 with two increments of advancement in each cycle.

Referring now to FiGURE 9, which schematically shows the path of the needles 26 and 28 through the web, the letter B represents the path of the reciprocating needles 28 through the web when the web is moved in step-by-step increments, the movement of the web being indicated just after the needles 28 begin their penetration. As shown in the lower portion of FIGURE 9, the path B is somewhat horizontal as the needles 23 start into the web but once the web is stopped and the needles 28 continue their travel through the web, the path is vertical. Likewise, the needles 26 penetrating the top side of the web 19 have a path through the same as represented by the letter C. Their path is similar to the path of the needles 28 in that adjacent the upper surface and when the needles 26 first enter the web, the fibers adjacent the surface are dragged in a substantially horizontal direction as the web is moving perpendicular to the vertical movement of the needles. Once the web'is stopped and with the needles 26 continuing their downward movement, some of the fibers moved horizontally are then moved vertically as well as other fibers which are picked up as the needles descend through the web. FIGURE 9 which represents a pair of point-on-point needles 26 and 28 clearly illustrates that the point of penetration on surface of the web of one needle is at the point which the oppositely disposed aligned needle extended out of the web on the previous penetration stroke. This arrangement results in some of the surface and subsurface fibers of the web being oriented toward the opposite surface and then entangled with some of these surface fibers and oriented parallel to this suriace and back toward the first rnentioned surface of the web.

Referring now to FIGURE 4, the pattern 22 of needles 26 is shown, it being understood that the pattern 24 of the needles 28 is an identical mirror image of pattern 22 as the needles of one pattern are in alignment point-onpoint with the needles of the other pattern. The needles 26 are arranged in a plurality of rows extending transverse of the direction of travel of the web It The rows are staggered so that more needles may be punching the web transversely of the same in each widthwise inch. In

other words, because the size of the needles will not ermit the needles to be placed in close enough spaced relationship widthwise of the web, rows of needles are provided with the rows being staggered so as to provide a high number of needles punching the web for every Widthwise inch of the web.

It has been found that to obtain a needled or non-woven fabric having the desired strength characteristics and density, the web 1 must be punched at least 1,000 times/ sq. inch of area as it passes through the throat 3d. Preferably, it is desirable to punch the fabric more than 1,060 times/sq. inch to obtain a better interlacing effect. Further, in accomplishing a high number of punches/ sq. inch, it is preferable to approximately balance the number of widthwise punches per inch of the web with the number of punches each needle makes per linear inch of the web. For example, if the rows of needles of the upper needle pattern 22 are so staggered that for one widthwise inch of the web, there is 49 punches and the web is advanced onetwentieth of an inch between each successive penetration of the patterns 22 and 24-, movement of the web entirely through the pattern will result in 800 punches/sq. inch by the top pattern 22'. Likewise, the lower pattern 24 will have 860 punches/sq. inch for one pass of the web through the machine, thus, resulting in a total 1,660 punches/sq. inch. By arranging the needles in staggered rows spaced linearly with respect to the web and extending widthwise of the same, it will be understood that complete interlacing of fibers is accomplished by the time the web has passed completely through the throat it). This may be seen by referring to FIGURES 6 and 7. In FIGURE 6, it is assumed that the needle 26 is one of the first needles to penetrate the web as the web is moving from left to right. In FIGURE 7 assuming that the needle 23 is oppositely disposed to and on point with the needle 25 in FIGURE 6, it will be noted that the web has moved a small increment of distance as determined above and that other fibers will have been picked up and oriented in the manner described. As the web it) continues to pass through the throat 3i and as it approaches the other end of the throat, interlacing by point-on-point needles 26 and 28 is repeated in much the same manner as a sewing machine operation in that the fibers are interlaced back and forth between the surfaces of the web. While FIGURES 6 and 7 show only one pair of aligned point-on-point needles 26 and 28, it must be realized that such an operation as described above is being accomplished by each pair of point-on-point needles 26 and 28 with no pair penetrating the same holes as another pair.

To accomplish effective interlacing by the above described method, it has been found that each needle pattern 22 and 24 must have an array of needles which will provide a range of needle punches per widthwise inch of the Web ll) of about 25 to about 50. Thus, in effect, there will be 25 to 50 paths of punches as the web is advancing through the needle patterns 22 and 24. With the above range of widthwise punches, it has been found that each needle of each pair of point-on-poin needles should penetrate the web in in a range of 6 to 30 penetrations per linear inch of web. This is accomplished by moving the web in step-by-step increments of onesixth to one-thirtieth of an inch for each successive penetration of a needle pattern.

Barb penetration, which is the distance of penetration through the web of the barb closest to the point of the needle, has been accomplished in a range from the surface of the web opposite the surface of penetration to a point where the aforesaid barb extends one-half of an inch from the surface. A range of barb penetration for maximum interlacing has been found to be three-sixteenths of an inch or greater whereas it has been found that maximum interlooping plus some interlacing is obtained in a range from the surface of the web to one-eighth of an inch below the surface.

interlacing gives the resulting non-woven fabric good tensile and separation. Also, interlacing provides good compactness and density to the produced fabric. However, non-woven fabric made entirely by interlacing of the fibers is not entirely satisfactory when the fabric must be submitted to a subsequent napping operation on its surfaces. Such an operation breaks down or destroys the interlacing structure and reduces the strength of the fabric. Where napping is required, it has been found desirable to have some interlooping of the subsurface fibers of the web so that the strength of the fabric is not adversely reduced by napping. The proportion of interlooping has been found to increase with a larger number of penetrations per lineal inch of web in the range mentioned above as well as at the lower end of the barb penetration range is. where the barb nearest the needle point extends just to the surface or slightly through the surface. Where there is maximum barb penetration and approximately 1%) punches per linear inch of web, the fibers are interlaced with little or no interlooping. On the other hand, where there is minimum barb penetration and for example 30 punches per lineal inch of web, the fibers are interlaced and interlooped.

FIGURE 3 of the drawings illustrates schematically the web It) having fibers which are both interlaced and interlooped. Such entanglement of fibers results in a needle-cl or non-woven fabric having a strength and compactness associated with woven fabrics. The fabric can be mapped so that it obtains a surface softness which makes it highly desirable for use in blankets and outerwear.

Referring back to FIGURES 1, 2 and 3, the improved needle punching apparatus 12 for accomplishing the above described method is best illustrated. The needle punching apparatus 12 includes a frame structure 44- made from suitable vertical standards 45, side frame members 48 and cross members 5%. Mounted on the upper side frame members 48 on each side of the frame structure 4d are a pair of spaced parallel vertical plates 52 which are adapted to support therebetween the guide plates 32 and .34 respectively. In more detail, the plates 52 are provided with slots 54- extending vertically downwardly from their upper edge, the slots 54 being adapted to receive studs 56 of bracket members 58 which are fixedly secured to the upper surface of the upper plate 32. The lower plate 34 is supported by L-shaped brackets 60 welded to the side plates 52 and to the bottom of the guide plate 34 As is now evident, the upper plate 32 may be adjusted relative the lower plate 34 by supporting the studs 56 at a desired height in the slots 54.

Side plates 52 are provided with the horizontally extending slots 62 and 6 Slots 62 of side plates 52 are adapted to receive ends of a shaft 66 which supports one pulley 68 of an endless conveyor structure 70. The portion of the shaft 66 which extends outwardly of the plate 52 shown in FIGURE 1 is provided with a drive sprocket 72;.

Slots 64 in plates 52 are adapted to receive the ends of a shaft '74 which supports an outfeed roller 76. Carried outwardly of the plates 52 on the end of the shaft '74 is a drive sprocket 78 (FIGURE 1). The other end of the shaft 74 is coupled to a one-way clutch and brake assembly 80 (FIGURE 2). A drive chain 82 extending around the sprockets 72 and 7t; and an idler sprocket 84 cause the pulley 62 to be rotated in step-by-step increments when the shaft i4 is rotated in step-by-step increments by the one-way clutch and brake assembly 80.

Cooperating with the outfeed roller '76 is a weighted roller 86 carried on the shaft 83 supported in diametrically opposed slots 90 provided in plates 52. The shaft 33 is provided on its outer ends with weights 92 so that the roller 86 will bear against the upper surface of the non-woven fabric 14 as it is discharged from the machine.

Mounted on the drive member of the one-way clutch 8b is a crank arm 94. A connecting arm 96 (FIGURE 1) connects the crank $4 with a disk or wheel 98 keyed 8,11 2 to a shaft 1% rotatably supported in the bearing pillows 132. Shaft ill-ill, carries a drive Wheel 3% which is rotated by a belt M6 coupled to a source tpower such as an electric motor 198. As will now be understood,

e CORLJZ of plates and is such that they conform to the web it IS compressed i.c. they allow no up and down flapping motion of the web driving the needling JCEES.

continuous rotation of the snaft ill-5i by the motor fi 5 A flywheel mounted on the shaft 135 provides will cause the crank $4 to oscillate back and forth. Since sufficient inertia to the drive mechanism of the apparatus the crank 94 is connected to he drive member of the once the apparatus is star-ted so that it reduces the power one-way clutch and brake assembly 3 3, clockwise movenecessary to drive the sam Any suitable braking means merit of the crank \viH cause rotation of the oufeed roller may be used to compensate for inertia of the flywheel '76 as Well as the infced conveyor '79. During counter- 10 and assist in stopping the apparatus after the motor clockwise movement of the crank 94, the roller 76 and is shut off. the conveyor '59 will be stationary and consequently, Throu hout the specification novel fabric structure there will be no feed of the web 1d through and out of or material produce by the novel method and apparatus the machine. has been referred to as a needled or non-woven fabric As previously stated, the upper n edle pattern 2.2 instructure. lt will be understood that the term needled cl les a plurality of downr /ardly exten g needles 26 or the term non-woven includes any fabric structure v rena the lower needle pattern .tdes a plurnade primarily from a Web or a bad of loosely matted rality or upwardly extending needles 2%. The needles noers with or without a woven or non-woven scrim. 26 and are arranged to pass through aligned While the obiects and advantages of the method and apbc-les provided in upper and wer web paratus of the present invention have been fully and etplaces and 3d respect y. T needles 26 are secured fectively accomplished, it will be understood that the imin a needle board or holder 313 fixedly secured to a proved method and/or apparatus is subject to some reciproca plate 11 by bolts, clamps or other suitable changes and inoclilictions without departing from the prinmeans. The rociprocatir late 11 5 is adjustrbly ciplcs and scone of the invention involved. Therefore, ed on a pair of recipron g rods 11?; carvertical the terminology used in the specification is for the pur sleeves or slide bearings 12) supported on the upper side pose of description and not limitation, the scope of the frame members The lower set of needles are suitinvention being defined the claims. ably supported in a needle board or holder 2 fixedly I claim: supp rted on a rec'procating plate 124 Plate 124 is ad- 1. A machine for making a ncedled fabric from a web justably supported on the reciprocating rods 13in spaced 30 of loosely matted fibers comprising: opposed sets of relationship benea" "e upper needle board 11?. and plate needles, the needles of one set having their points aligned lid. As shown in lGURE 3, the rods 11% are threaded point-on-poin-t with the needles of the other set and having and by adjustment or" nuts 12-5, the lower plate 124 and the 1' paths of penetration substantially mirror-image and upper plate Elllcan be adjusted vertically with respect to op osite of the paths of penetration of the other set of each other so that the distance between the points of needles, means for advancing the Web between the sets needles and respectively can be varic of needles in intermittent step-by-step motion, m ans for Each lower othe reciprocating rods 118 is pivotalreciprocating and effecting alternate penetration of the ly connected as indicated at 13% to conne rods 132. web by said opposed sets in ap-alh substantially perpendic- The other end of each of the connecting rods 13?. is conulrr to surfaces or said we 0, and means coordinating said 'nected to cranks 13 mounted on the ends of a shaft 13-6 reciprocating means ith said Web advancing means i tably supported he bearing pillow blocks 14%. A whereby needles of said sets penetrate the su riace of said 'oclzet 42 carried on the shaft is driven by a chain web while said web is moving and continue penetration also tr ined around a sprocket r d on the through the web while said Web is stationary. drive shaft 16%. As is now ap eren by an pection of In a machine for making a needled fabric from a FlGURES l and 2, rotation of the drive shit 1% by the web of loosely matted fibers: a pair of opposed guide motor 168 will cause rotation of the cranks 13 3 so that the plates for the web defining a confined throat having a connecting arms 132 reciprocate the rods lid to simultagradually decreas ng infeed portion and a portion of neously move both needle patterns 24- in a path substantially constant thickness, each of said plates havnormal to the path of travel of the web fill through the ing a plurality of holes therein; opposed sets of needles machine. The reciprocation of the nee lle patterns 22 for passing through the holes in said plates into the Web and 24 is so timed with the intermittent feed of the web in a path substantially perpendicular to the surfaces of iii the the needles of each of the patterns will penetrate said web, the needles of one set having their points the web when the web is moving. However, as soon as alir ned point-on-point with the needles of the other set the needles of the particular pattern 22 or 24- enter and having paths or penetration substantially mirrorthe sur .ce of the web-the advancement of the webs image and opposite of the paths of penetration of the stops as the needles continue their movement through the paths or" the other set, means for advancing said web web and the web remains stationary until the needles of in intermittent step-by-step motion through the throat the particular pattern are with After the needles between said plates, means for reciprocating said sets of one of the pattern are withdrawn from the surface of its to effect alternate penetrations of the web; of the web and as the needles of the pattern are beginning and means coordinating said reciprocating means with to generate the opposie surface, the web will begin its said web advancing means whereby said needles of said advancement. When e web again stops, needle sets penetrate the surfaces of said web while said web penetration continues through theiveb. is moving and continue penetration through the Web Referring now to *FlGURE 3, it will be noted that the while said web is stationary. first few r we of needles and 28 of upper and lower 3. The machine defined in claim 2 wherein some of needle patterns 22 and 2 respectively pass through the the needles of each of the opposed sets of needles pass curved inlet portions 3s and 38 of the guide plates 32 and through holes in said plates and enter the gradually Some of these needles do not pass completely decreasing infced portion of the throat, thereby corn tlough the web as heretofore described but merely pressing the web. enter the web and compress the Web in the tapering in- 4. In a device for needling a Web of loosely matted feed portion of throat In other words, the needles fibers: 0- osed sets of needles, the needles of one set in this forward portion are not entirely eiiective to cause having tl: points aligned with the needles of the other interlacing and/or i"terlooping of the loosely matted fibers set and having paths of penetration substantially mirrorbut they do compr s the web to proper thickness and. go and opposite of the paths of penetration of the density for through the confined throat other set of needles, each set including a plurality of rows of needles spaced longitudinally to a direction of travel of the web and extending transversely of the web, the needles or" one row being staggered with respect to the -eedles of another row of the same set in a direction transversely of the direction of travel of the web; means for advancing the web in intermittent step-by-step motion between the opposed sets of needles; means for effecting reciprocation and causing alternate penetration of the web by said opposed sets of needles, and means coordinating said reciprocating means and Web advancing means whereby needles of said sets penetrate the surfaces of said web while said web is moving and continue penetration through the web while said web is stationary.

5, A machine for making a needled fabric from a web of loosely matted fibers comprising: opposed sets of needles, the needles of one set having paths of penetration substantially mirror-image and opposite of the paths of penetration of the other set of needles, means for advancing the web between the sets of needles in intermittent step-by-step motion, means for effecting alternate penetration of the web by said opposed sets of needles in substantially mirror-image and opposed paths of penetration, and means coordinating said advancing means with said penetration means whereby fibers oriented by one set of needles during the penetration path of the same are reoriented by the other set of needles during the latter sets next penetration path with some other fibers being oriented and entangled therewith.

6. A machine as claimed in claim wherein the needles of one set have their points aligned point-onpoint with the needles of the other set and wherein said sets of needles reciprocate in a path perpendicular to the surface of the web.

7. A machine for making a needled fabric from a Web f loosely matter fibers comprising: a pair of opposed guide plates for the web defining a confined throat having a gradually decreasing infeed portion and a portion of substantially constant thickness, each of said plates having a plurality of holes therein in the infeed portion and in the portion of substantially constant thickness; opposed sets of needles for passing through the holes in said plates respectively into the web, some of the needles of each of said sets passing through holes in said plates into the gradually decreasing infeed portion of the throat so as to compress the web, the needles of one set having paths of penetration substantially mirror-image and opposite of the paths of penetration of the other sets; means for advancing the web in an intermittent step-bystep motion through the throat between said plates; means for effecting alternate penetration of the web by said opposed sets of needles in the substantially mirrorimage and opposed paths of penetration, and means coordinating said advancing means with said penetration means whereby fibers oriented by one set of needles during the penetration path of the same are reoriented by the other set of needles during the latter sets next penetration path with some other fibers being oriented and entangled therewith.

References Cited in the file of this patent UNITED STATES PATENTS 502,376 Ochs I Aug. 1, 1893 1,211,821 Carlson et al. Ian. 9, 1917 2,377,564 Lundgen June 5, 1945 2,896,302 Costello July 28, 1959 

1. A MACHINE FOR MAKING A NEEDLED FABRIC FROM A WEB OF LOOSELY MATTED FIBERS COMPRISING: OPPOSED SETS OF NEEDLES, THE NEEDLES OF ONE SET HAVING THEIR POINTS ALIGNED POINT-ON-POINT WITH THE NEEDLES OF THE OTHER SET AND HAVING THEIR PATHS OF PENETRATION SUBSTANTIALLY MIRROR-IMAGE AND OPPOSITE OF THE PATHS OF PENETRATION OF THE OTHER SET OF NEEDLES, MEANS FOR ADVANCING THE WEB BETWEEN THE SETS OF NEEDLES IN INTERMITTENT STEP-BY-STEP MOTION, MEANS FOR RECIPROCATING AND EFFECTING ALTERNATE PENETRATION OF THE WEB BY SAID OPPOSED SETS IN A PATH SUBSTANTIALLY PERPENDICULAR TO SURFACES OF SAID WEB, AND MEANS COORDINATING SAID RECIPROCATING MEANS WITH SAID WEB ADVANCING MEANS WHEREBY NEEDLES OF SAID SETS PENETRATE THE SURFACE OF SAID WEB WHILE SAID WEB IS MOVING AND CONTINUE PENETRATION THROUGH THE WEB WHILE SAID WEB IS STATIONARY. 